Liner hanger with slip joint sealing members and method of use

ABSTRACT

An apparatus ( 200 ) and method for repairing an opening ( 130 ) in a wellbore casing ( 110 ). The apparatus ( 200 ) and method couple a floating tubular ( 250 ) member in opposing relation to the opening ( 130 ) in the wellbore casing ( 110 ).

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date of U.S.provisional patent application serial No. 60/221,443, attorney docketnumber 25791.45, filed on Jul. 28, 2000, the disclosure of which isincorporated herein by reference.

[0002] This application is related to the following co-pendingapplications: (1) U.S. patent application Ser. No. 09/440,338, attorneydocket number 25791.9.02, filed on Nov. 15, 1999, which claimed benefitof the filing date of U.S. provisional patent application serial No.60/108,558, attorney docket number 25791.9, filed on Nov. 16, 1998, (2)U.S. patent application Ser. No. 09/454,139, attorney docket number25791.3.02, filed on Dec. 3, 1999, which claimed benefit of the filingdate of U.S. provisional patent application serial No. 60/111,293, filedon Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350,attorney docket number 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional patent applicationserial No. 60/119,611, attorney docket number 25791.8, filed on Feb. 11,1999, (4) U.S. patent application Ser. No. 09/510,913, attorney docketnumber 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit ofthe filing date of U.S. provisional patent application serial No.60/121,702, attorney docket number 25791.7, filed on Feb. 25, 1999, (5)U.S. patent application Ser. No. 09/511,941, attorney docket number25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/121,907,attorney docket number 25791.16, filed on Feb. 26, 1999, (6) U.S. patentapplication Ser. No. 09/523,460, attorney docket number 25791.11.02,filed on Mar. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application serial No. 60/124,042, attorneydocket number 25791.11, filed on Mar. 11, 1999, (7) U.S. patentapplication Ser. No. 09/559,122, attorney docket number 25791.23.02,filed on Apr. 26, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application serial No. 60/131,106, attorneydocket number 25791.23, filed on Apr. 26, 1999, (8) U.S. patentapplication Ser. No. ______, attorney docket number 25791.17.02, filedon ______ , which claimed the benefit of the filing date of U.S.provisional patent application serial No. 60/137,998, attorney docketnumber 25791.17, filed on Jun. 7, 1999, (9) U.S. provisional patentapplication serial No. 60/143,039, attorney docket number 25791.26,filed on Jul. 9, 1999, (10) U.S. provisional patent application serialNo. 60/146,203, attorney docket number 25791.25, filed on Jul. 29, 1999,the disclosures of which are incorporated by reference; (11) U.S.provisional patent application serial No. 60/183,546, attorney docketnumber 25791.10, filed on Feb. 18, 2000; (12) U.S. patent applicationSer. No. 09/512,895, attorney docket number 25791.12.02, filed on Feb.24, 2000, which claimed the benefit of the filing date of U.S.provisional patent application serial No. 60/121,841, attorney docketnumber 25791.12, filed on Feb. 26, 1999; (13) U.S. provisional patentapplication serial No. ______, attorney docket number 25791.38, filed onJun. 19, 2000; (14) U.S. provisional patent application serial No.60/162,671, attorney docket number 25791.27, filed on Nov. 1, 1999; (15)U.S. provisional patent application serial No. 60/159,039, attorneydocket number 25791.36, filed on Oct. 12, 1999; (16) U.S. provisionalpatent application serial No. 60/159,033, attorney docket number25791.37, filed on Oct. 12, 1999; (17) U.S. provisional patentapplication serial No. 60/165,228, attorney docket number 25791.39,filed on Nov. 12, 1999; and (18) U.S. provisional patent applicationserial No. ______, attorney docket number 25791.46, filed on ______, thedisclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0003] This invention relates generally to wellbore casings, and inparticular to apparatus and methods for repairing wellbore casings.

[0004] Conventionally, when a wellbore casing is damaged, a tubularliner is positioned within the damaged section of the wellbore casing inorder to provide structural support and prevent the undesired outflow ofdrilling fluid into the formation or inflow of fluid from the formationinto the borehole. However, conventional tubular liners used forrepairing damaged sections of wellbore casings suffer from a number ofserious drawback. For example, conventional tubular liners used forrepairing damaged sections of wellbore casings are not designed toaccommodate variable loading conditions.

[0005] The present invention is directed to overcoming one or more ofthe limitations of the existing apparatus and methods for repairingdamaged sections of wellbore casings.

SUMMARY OF THE INVENTION

[0006] According to one aspect of the present invention, a method ofrepairing a damaged section of a wellbore casing is provided thatincludes removing at least a portion of the damaged section of thewellbore casing to create an opening in the wellbore casing, andcovering at least a portion of the opening in the wellbore casing with afloating tubular member.

[0007] According to another aspect of the present invention, a radiallyexpandable tubular member for repairing an opening in a wellbore casingis provided that includes a tubular member and a slip joint coupled tothe exterior surface of the tubular member.

[0008] According to another aspect of the present invention, anapparatus for repairing an opening in a wellbore casing is provided thatincludes a tubular support member including a first passage, anexpansion cone coupled to the tubular support member including a secondpassage fluidicly coupled to the first passage, an expansion conelauncher coupled to the expansion cone including a shoe having anexhaust passage, and an expandable tubular member coupled to theexpansion cone launcher including one or more sealing members havingslip joints.

[0009] According to another aspect of the present invention, anapparatus is provided that includes a wellbore casing including anopening, and a floating tubular member coupled to the wellbore casing inopposing relation to the opening.

[0010] According to another aspect of the present invention, a systemfor repairing a damaged section of a wellbore casing is provided thatincludes means for removing at least a portion of the damaged section ofthe wellbore casing to create an opening in the wellbore casing, andmeans for covering at least a portion of the opening in the wellborecasing with a floating tubular member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 is a cross-sectional view illustrating a wellbore casingincluding a damaged section.

[0012]FIG. 2 is a fragmentary cross-sectional view illustrating theintroduction of a milling device into the wellbore casing of FIG. 1.

[0013]FIG. 3 is a fragmentary cross-sectional view illustrating theremoval of at least a portion of the damaged section of the wellborecasing using the milling device to form an opening in the wellborecasing of FIG. 2.

[0014]FIG. 4 is a fragmentary cross-sectional view illustrating theplacement of a repair apparatus for covering the opening in the wellborecasing of FIG. 3.

[0015]FIG. 5 is a fragmentary cross-sectional view illustrating theinjection of fluidic materials into the repair apparatus of FIG. 4.

[0016]FIG. 6 is a fragmentary cross-sectional view illustrating thepressurization of the interior of the repair apparatus of FIG. 5.

[0017]FIG. 7 is a fragmentary cross-sectional view illustrating thecompletion of the radial expansion of the expandable tubular member ofthe repair apparatus of FIG. 6.

[0018]FIG. 8 is a cross-sectional view illustrating the milling out ofthe shoe of the radially expanded tubular member of FIG. 7.

[0019]FIG. 9 is a cross-sectional illustration of an embodiment of upperand lower sealing members that include internal slip joints.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

[0020] An apparatus and method for repairing an opening in a damagedsection of a wellbore casing within a subterranean formation isprovided. The apparatus and method provides a system for repairing anopening in a damaged section of a wellbore casing within a subterraneanformation in which a tubular member is radially expanded into contactwith the wellbore casing. The physical connection between the radiallyexpanded tubular member and the wellbore casing is preferably compliantand permits movement of the radially expanded tubular member relative tothe wellbore casing in at least the longitudinal direction. In thismanner, the radially expanded tubular member is capable of absorbing awide range of loading conditions.

[0021] Referring initially to FIG. 1, a wellbore 100 positioned within asubterranean formation 105 includes a preexisting casing 110 thattraverses a producing formation 115. The portion of the casing 110 thattraverses the producing formation 115 includes a damaged section 120. Aswill be recognized by persons having ordinary skill in the art, thedamaged section 120 may be caused by, for example, structuralinstabilities in the producing formation 115 such as, for example,subsidence that can cause buckling of the wellbore casing 110.

[0022] Referring to FIGS. 2 and 3, in order to repair the damagedsection 120 of the wellbore casing 110, a conventional milling device125 is then inserted into the wellbore casing 110. The milling device125 is then used to remove at least a portion of the damaged section 120of the wellbore casing 110 and thereby form an opening 130 in thewellbore casing 110.

[0023] Referring to FIG. 4, an apparatus 200 for repairing the opening130 in the wellbore casing 110 may then be positioned within thewellbore casing proximate the opening in the wellbore casing.

[0024] The apparatus 200 includes a tubular support member 205 having alongitudinal passage 210 and a transverse passage 215 that is coupled toan expansion cone 220 having a longitudinal passage 225 that isfluidicly coupled to the longitudinal passage 210. The expansion cone220 is at least partially received within an expansion cone launcher 230that includes a thin-walled annular member 235 and a shoe 240 having anexhaust passage 245. An expandable tubular member 250 extends from theexpansion cone launcher 230 that includes upper and lower sealingmembers 255 a and 255 b affixed to the exterior surface of theexpandable tubular member. A sealing cup 260 is attached to the exteriorsurface of the tubular support member 205 for preventing foreignmaterials from entering the interior of the expandable tubular member250.

[0025] In a preferred embodiment, the apparatus 200 is provided asdisclosed in one or more of the following: (1) U.S. patent applicationSer. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov.15, 1999, which claimed benefit of the filing date of U.S. provisionalpatent application serial No. 60/108,558, attorney docket number25791.9, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No.09/454,139, attorney docket number 25791.3.02, filed on Dec. 3, 1999,which claimed benefit of the filing date of U.S. provisional patentapplication serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S.patent application Ser. No. 09/502,350, attorney docket number25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional patent application serial No.60/119,611, attorney docket number 25791.8, filed on Feb. 11, 1999, (4)U.S. patent application Ser. No. 09/510,913, attorney docket number25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of thefiling date of U.S. provisional patent application serial No.60/121,702, attorney docket number 25791.7, filed on Feb. 25, 1999, (5)U.S. patent application Ser. No. 09/511,941, attorney docket number25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/121,907,attorney docket number 25791.16, filed on Feb. 26, 1999, (6) U.S. patentapplication Ser. No. 09/523,460, attorney docket number 25791.11.02,filed on Mar. 10, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application serial No. 60/124,042, attorneydocket number 25791.11, filed on Mar. 11, 1999, (7) U.S. patentapplication Ser. No. 09/559,122, attorney docket number 25791.23.02,filed on Apr. 26, 2000, which claimed the benefit of the filing date ofU.S. provisional patent application serial No. 60/131,106, attorneydocket number 25791.23, filed on Apr. 26, 1999, (8) U.S. patentapplication Ser. No. ______, attorney docket number 25791.17.02, filedon Apr. 26, 2000, which claimed the benefit of the filing date of U.S.provisional patent application serial No. 60/137,998, attorney docketnumber 25791.17, filed on Jun. 7, 1999, (9) U.S. provisional patentapplication serial No. 60/143,039, attorney docket number 25791.26,filed on Jul. 9, 1999, (10) U.S. provisional patent application serialNo. 60/146,203, attorney docket number 25791.25, filed on Jul. 29, 1999,the disclosures of which are incorporated by reference; (11) U.S.provisional patent application serial No. 60/183,546, attorney docketnumber 25791.10, filed on Feb. 18, 2000; (12) U.S. patent applicationSer. No. 09/512,895, attorney docket number 25791.12.02, filed on Feb.24, 2000, which claimed the benefit of the filing date of U.S.provisional patent application serial No. 60/121,841, attorney docketnumber 25791.12, filed on Feb. 26. 1999; (13) U.S. provisional patentapplication serial No. ______, attorney docket number 25791.38, filed onJun. 19, 2000; (14) U.S. provisional patent application serial No.60/162,671, attorney docket number 25791.27, filed on Nov. 1, 1999; (15)U.S. provisional patent application serial No. 60/159,039, attorneydocket number 25791.36, filed on Oct. 12, 1999; (16) U.S. provisionalpatent application serial No. 60/159,033, attorney docket number25791.37, filed on Oct. 12, 1999; and (17) U.S. provisional patentapplication serial No. 60/165,228, attorney docket number 25791.39,filed on Nov. 12, 1999, the disclosures of which are incorporated hereinby reference.

[0026] As illustrated in FIG. 4, during placement of the apparatus 200within the wellbore casing 110, fluidic materials displaced by theapparatus 200 are conveyed through the longitudinal passages 210 and 225to the transverse passage 215. In this manner, surge pressures duringthe placement of the apparatus 200 within the wellbore casing 110 areminimized. Furthermore, as illustrated in FIG. 4, the apparatus 200 ispreferably positioned with the tubular member 250 in opposing relationto the opening 130 in the wellbore casing 110. In this manner, the upperand lower sealing members 255 a and 255 b may engage portions of thewellbore casing 110 above and below the opening 130 after radiallyexpanding the tubular member 250.

[0027] As illustrated in FIG. 5, the transverse passage 215 may then beclosed and fluidic materials injected into the apparatus 200 through thelongitudinal passage 210. In this manner, any blockages within any ofthe passages 210, 225, and 245 may be detected by monitoring theoperating pressure whereby an increase in operating pressure abovenominal, or predetermined, conditions may indicate a blockage of one ofthe passages.

[0028] As illustrated in FIG. 6, a plug 265 or other conventional stopmember may then be introduced into the fluidic materials injected intothe apparatus 200 through the passage 210, and the plug 265 may bepositioned within the passage 245. In this manner, the passage 245 maybe sealed off. Thus, continued injection of fluidic materials into theapparatus 200 through the passage 210 may thereby pressurize a region270 below the expansion cone 220.

[0029] As illustrated in FIG. 7, continued pressurization of the region270 causes the expansion cone 220 to radially expand the expandabletubular member 250 off of the expansion cone. In this manner, the upperand lower sealing members 255 a and 255 b preferably engage the interiorwalls of the wellbore casing 110 above and below the opening 130 therebysealing off the opening. In a preferred embodiment, during the radialexpansion process, the tubular support member 205 is raised out of thewellbore 100.

[0030] As illustrated in FIG. 8, the shoe 240 may then be removed usinga conventional milling device. In this manner, exploration andproduction of subterranean regions beyond the opening 130 in thewellbore casing 110 may be conducted.

[0031] In several alternative embodiments, the upper sealing member 255a or the lower sealing member 255 b are omitted from the tubular member250. In this manner, the radially expanded tubular member 250 ispermitted to float relative to the wellbore casing 110. Furthermore, inthis manner, relative longitudinal and/or transverse movements of thesections of the wellbore casing 110 above and below the opening 130 maybe optimally accommodated by the radially expanded tubular member 250.Finally, in this manner, damage to the radially expanded tubular member250 that can be caused by longitudinal stresses, such as buckling, maybe minimized or eliminated.

[0032] In another alternative embodiment, as illustrated in FIG. 9, theupper sealing member 255 a and/or the lower sealing member 255 b includeinternal slip joints 300 a and 300 b in order to permit the radiallyexpanded tubular member 250 to float relative to the wellbore casing110. In this manner, relative longitudinal and/or transverse movementsof the sections of the wellbore casing 110 above and below the opening130 may be optimally accommodated. Furthermore, in this manner, damageto the radially expanded tubular member 250 that can be caused bylongitudinal stresses, such as buckling, may be minimized or eliminated.

[0033] In a preferred embodiment, the sealing members 255 a and 255 bpermit the radially expanded tubular member 250 to move in thelongitudinal direction while also maintaining a fluidic seal. In severalalternative embodiments, the sealing members 255 a and 255 b arefabricated from a resilient material such as, for example, synthetic ornatural rubber.

[0034] It is understood that variations may be made in the foregoingwithout departing from the scope of the invention. For example, theapparatus 200 may be used to repair, for example, a wellbore casing, apipeline, or a structural support.

[0035] Although illustrative embodiments of the invention have beenshown and described, a wide range of modification, changes andsubstitution is contemplated in the foregoing disclosure. In someinstances, some features of the present invention may be employedwithout a corresponding use of the other features. Accordingly, it isappropriate that the appended claims be construed broadly and in amanner consistent with the scope of the invention.

What is claimed is:
 1. A method of repairing a damaged section of a wellbore casing, comprising: removing at least a portion of the damaged section of the wellbore casing to create an opening in the wellbore casing; and covering at least a portion of the opening in the wellbore casing with a floating tubular member.
 2. The method of claim 1, further comprising: coupling the tubular member to the wellbore casing with a slip joint.
 3. The method of claim 1, wherein covering at least a portion of the opening in the wellbore casing with a floating tubular member comprises: radially expanding at least a portion of the tubular member into contact with the wellbore casing.
 4. The method of claim 3, wherein the radially expanded tubular member contacts the wellbore casing above and below the opening.
 5. The method of claim 3, wherein the radially expanded tubular member only contacts the wellbore casing above the opening.
 6. The method of claim 3, wherein the radially expanded tubular member only contacts the wellbore casing below the opening.
 7. A radially expandable tubular member for repairing an opening in a wellbore casing, comprising: a tubular member; and a slip joint coupled to the exterior surface of the tubular member.
 8. An apparatus for repairing an opening in a wellbore casing, comprising: a tubular support member comprising a first passage; an expansion cone coupled to the tubular support member comprising a second passage fluidicly coupled to the first passage; an expansion cone launcher coupled to the expansion cone comprising a shoe having an exhaust passage; and an expandable tubular member coupled to the expansion cone launcher comprising one or more sealing members having slip joints.
 9. An apparatus, comprising: a wellbore casing comprising an opening; and a floating tubular member coupled to the wellbore casing in opposing relation to the opening.
 10. A system for repairing a damaged section of a wellbore casing, comprising: means for removing at least a portion of the damaged section of the wellbore casing to create an opening in the wellbore casing; and means for covering at least a portion of the opening in the wellbore casing with a floating tubular member.
 11. The system of claim 10, further comprising: means for coupling the tubular member to the wellbore casing with a slip joint.
 12. The system of claim 10, wherein the means for covering at least a portion of the opening in the wellbore casing with a floating tubular member comprises: means for radially expanding at least a portion of the tubular member into contact with the wellbore casing.
 13. The system of claim 12, wherein the means for radially expanded tubular member comprises: means for radially expanding the tubular member into contact with the wellbore casing above and below the opening.
 14. The system of claim 12, wherein the radially expanded tubular member only contacts the wellbore casing above the opening.
 15. The system of claim 12, wherein the radially expanded tubular member only contacts the wellbore casing below the opening. 